US9056438B2 - Curable composition, articles comprising the curable composition, and method of making the same - Google Patents

Curable composition, articles comprising the curable composition, and method of making the same Download PDF

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US9056438B2
US9056438B2 US13/461,957 US201213461957A US9056438B2 US 9056438 B2 US9056438 B2 US 9056438B2 US 201213461957 A US201213461957 A US 201213461957A US 9056438 B2 US9056438 B2 US 9056438B2
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curable composition
composition according
melting
layer
polyepoxide
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US20130295311A1 (en
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Eric G. Larson
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3M Innovative Properties Co
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3M Innovative Properties Co
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Priority to SG11201407112UA priority patent/SG11201407112UA/en
Priority to KR1020147033375A priority patent/KR101979977B1/ko
Priority to PCT/US2013/035410 priority patent/WO2013165648A1/en
Priority to TW102114252A priority patent/TWI580751B/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
    • C08G59/42—Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof
    • C08G59/4284—Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof together with other curing agents
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/08—Metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/17—Amines; Quaternary ammonium compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/04—Homopolymers or copolymers of esters
    • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
    • C08L33/062—Copolymers with monomers not covered by C08L33/06
    • C08L33/068—Copolymers with monomers not covered by C08L33/06 containing glycidyl groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J163/00—Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2405/00—Adhesive articles, e.g. adhesive tapes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/14—Semiconductor wafers
    • C08F2220/1825—
    • C08F2220/325—
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/08—Metals
    • C08K2003/085—Copper
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/14—Layer or component removable to expose adhesive
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y10T428/2848—Three or more layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31511—Of epoxy ether

Definitions

  • the present disclosure broadly relates to curable compositions and articles including them.
  • Wafers of semiconductor material such as silicon and gallium-arsenide with integrated circuits formed thereon have a relatively large diameter.
  • IC integrated circuits
  • a wafer is adhered to a pressure-sensitive adhesive tape, sometimes called a dicing tape, and diced into IC chips.
  • the IC chips (dice) are then removed from the dicing tape, and an adhesive (sometimes called a die attach adhesive) is applied to the chip or to a substrate, the chip is placed on the substrate and the adhesive is cured to attach the die to the substrate.
  • Die attach adhesives when cured, may be electrically and thermally conductive for some applications.
  • the die attach adhesive may be applied to the surface of a chip that is opposite the circuits or it may be applied directly to the substrate to which the chip will be bonded. After bonding to the substrate with the die attach adhesive, the resultant assembly may be subjected to elevated temperature, for example, as may occur if subjected to a solder reflow step during assembly of an electronic device.
  • the present disclosure provides a curable composition comprising:
  • high-melting metal particles having a melting point above 300° C.
  • low-melting metallic particles having a melting point of less than or equal to 300° C.
  • a fluxing curing agent comprising:
  • the present disclosure provides an adhesive article comprising a layer of curable composition according to the present disclosure disposed on a removable liner.
  • the present disclosure provides a composite article comprising:
  • the present disclosure provides a method of making a composite article, the method comprising affixing a layer of a curable composition according to the present disclosure to a semiconductor wafer.
  • adhesive compositions according to the present disclosure may be suitable for use as die attach adhesives that can be formed into a dimensionally-stable film (e.g., a sheet or tape).
  • a dimensionally-stable film e.g., a sheet or tape.
  • thermal energy such adhesive compositions undergo transient liquid phase sintering producing a thermally and electrically conductive adhesive composition that securely bonds the semiconductor die to a substrate (e.g., a printed circuit board or a flex circuit).
  • C q a term such as “C q ” used in reference to an organic group or molecule, where q is a number, means that the group or molecule has q carbon atoms;
  • electrically conductive means having a surface resistance of less than 10 ⁇ 2 ohms per square;
  • hydrocarbylene refers to a divalent radical formed by removing two hydrogen atoms from a hydrocarbon
  • (meth)acryl refers to acryl and/or methacryl
  • polyepoxide refers to a compound having more than one oxiranyl group (i.e., a three-membered ring formed by two carbon atoms and one oxygen atom that are connected to one another by single covalent bonds), also called an epoxy group.
  • electrically conductive compositions and/or articles according to the present disclosure have a bulk resistance of less than 10, 1, 0.1, 0.01, or even less than 10 ⁇ 3 ohms per centimeter.
  • FIG. 1 is cross-sectional side view of an exemplary adhesive article according to the present disclosure.
  • FIG. 2 is a cross-sectional side view of an exemplary composite article according to the present disclosure.
  • Curable compositions according to the present disclosure comprise: a) at least one polyepoxide; b) high-melting metal particles having a melting point above 300° C.; c) low-melting metallic particles having a melting point of less than or equal to 300° C.; and d) a fluxing curing agent comprising: a hydroxyalkyl-substituted tertiary amine; and at least one diacid compound represented by the formula: HO 2 C—Z 1 —CH 2 CH 2 CH 2 —Z 2 —CO 2 H wherein Z 1 and Z 2 independently represent a covalent bond or an aliphatic hydrocarbylene group, and wherein the at least one diacid compound comprises at least 50 percent of the total weight of carboxylic acids and anhydrides present in the curable composition.
  • the at least one polyepoxide may comprise one or more liquid and/or solid polyepoxides, however the amount of any liquid components in the curable composition is desirably kept at a sufficiently low level that the curable composition is capable of forming a dimensionally stable film that will not flow appreciably on storage and handling at ambient temperatures (e.g., at 25 degrees Celsius (° C.)).
  • the curable composition may comprise less than 50, 40, 30, 20, 10, 5, 1, or even less than 0.1 percent of liquid components such as polyepoxides.
  • Examples of useful epoxy resins include solid epoxy resins formed by reaction of bisphenol A or bisphenol F with epichlorohydrin, and mixtures of such resins.
  • commercially available solid epoxy resins having the trade designation “EPON” (e.g., EPON 1001F, EPON 1002F, EPON 1004F, EPON 1007F, EPON 1009F, EPON 2003, EPON 2002, EPON 2003, EPON 2004, EPON 2005, EPON 2014, EPON 2024, and EPON 2041) marketed by Momentive Specialty Chemicals, Columbus, Ohio.
  • Useful epoxy resins also include polymeric polyepoxides such as, for example, linear polymers having terminal epoxy groups (e.g., a diglycidyl ether of a polyoxyalkylene glycol), polymers having skeletal epoxy groups (e.g., polybutadiene polyepoxide), and polymers having pendant epoxy groups (e.g., a glycidyl methacrylate polymer or copolymer).
  • Polymeric polyepoxides may be pure compounds, but are generally mixtures or compounds containing one, two or more epoxy groups per molecule.
  • Epoxy resins that are both solid at ambient temperature and polymeric polyepoxides include, for example, commercially available solid epoxy resins having the trade designation “EHPE” (e.g., EHPE 3150 and EHPE 3180 cycloliphatic epoxy resins) available from Daicel Chemical Industries, Ltd., Tokyo, Japan.
  • Useful polymeric polyepoxides may also comprise an acrylic polymer having pendant epoxy groups such as, for example, copolymers of glycidyl acrylate and an acrylic monomer (e.g., a copolymer of glycidyl(meth)acrylate with butyl acrylate).
  • the at least one polyepoxide comprises a solid non-polymeric polyepoxide and a polymeric polyepoxide.
  • Useful high-melting metal particles have a melting point above 300° C. and include, for example, copper particles, silver particles, gold particles, palladium particles, platinum particles, nickel particles, cobalt particles, chromium particles, cobalt particles, aluminum particles, lead particles, zinc particles, iridium particles, osmium particles, rhodium particles, tungsten particles, molybdenum particles, ferrous particles (e.g., stainless steel particles), and indium tin oxide particles. These metals may be used alone or in an alloy of two or more kinds thereof, as long as the alloy has a melting point above 300° C.
  • the high-melting metal particles may be generally spherical, flaky, or amorphous, or may have another shape.
  • the high-melting metal particles may have any size, although desirably they have an average particle diameter (D 50 ) of from 0.1 to 10 microns, desirably from 0.2 to 7 microns, more desirably from 0.5 to 5 microns, and still more desirably from 1 to 3 microns.
  • the low melting point metallic particles are metallic particles that melt at or below 300° C., for example, less than about 275° C., or even less than about 225° C.
  • the low-melting metallic particles are typically alloys although this is not a requirement.
  • the low-melting metallic particles comprise at least one of tin, lead, indium, or bismuth.
  • solder alloys such as Sn 42 Bi 58 (
  • the weight ratio of the low melting point metallic particles and the high-melting metal particles is in a range of from 0.5 to 0.8, although other ratios may be used.
  • the low melting point metallic particles melts and/or sinters with the high melting metal particles thereby creating a conductive network. If the sintering temperature is sufficiently lower that the curing temperature of the curable composition, the composition will typically remain curable.
  • Conventional fluxing agents typically comprise acids (e.g., mineral acids and/or carboxylic acids) and acidic precursors (e.g., anhydrides) that can generate acids by hydrolysis or alcoholysis.
  • acids e.g., mineral acids and/or carboxylic acids
  • acidic precursors e.g., anhydrides
  • Fluxing curing agents in the present disclosure comprise a hydroxyalkyl-substituted tertiary amine and a diacid component.
  • the inventor believes that the hydroxyalkyl-substituted tertiary amine enhances fluxing of the high melting metal particles, at least when used in combination with a diacid of the fluxing curing agent.
  • the fluxing curing agent also facilitates curing of the polyepoxide component(s) of the curable composition. Accordingly, it is desirably present in an amount that is effective to accelerate at least partial cure (e.g., substantially cure or completely cure) the at least one polyepoxide (e.g., at a temperature of at least 170° C., 200° C., or even at least 225° C.), although this is not a requirement.
  • at least partial cure e.g., substantially cure or completely cure
  • the at least one polyepoxide e.g., at a temperature of at least 170° C., 200° C., or even at least 225° C.
  • the curable composition may further comprise one or more additional curatives (e.g., amines, thiols, anhydrides) for polyepoxides.
  • additional curatives e.g., amines, thiols, anhydrides
  • the hydroxyalkyl-substituted tertiary amine comprises from at least 0.1 to 10 percent, desirably 0.1 to 5 percent, and more desirably, from 0.5 to 3 percent by weight of the curable composition.
  • the hydroxyalkyl-substituted tertiary amine comprises a compound represented by the formula: NR 3 R 4 R 5 wherein R 3 represents a C 2 -C 4 hydroxyalkyl group, and R 4 and R 5 independently represent a C 2 -C 18 alkyl group or a C 2 -C 4 hydroxyalkyl group.
  • R 3 represents a C 2 -C 4 hydroxyalkyl group
  • R 4 and R 5 independently represent a C 2 -C 18 alkyl group or a C 2 -C 4 hydroxyalkyl group.
  • Examples include (2-hydroxyethyl)-diethylamine, 2-hydroxypropylisopropylmethylamine, (4-hydroxybutyl)dimethylamine, bis(2-hydroxyethyl)ethylamine, stearyldiethanolamine, and triethanolamine. Combinations of more than one hydroxyalkyl-substituted tertiary amine may also be used.
  • Fluxing curing agents according to the present disclosure also comprise at least one diacid compound represented by the formula: HO 2 C—Z 1 —CH 2 CH 2 CH 2 —Z 2 —CO 2 H wherein Z 1 and Z 2 independently represent a covalent bond or an aliphatic hydrocarbylene group.
  • suitable such compounds include Diels-Alder adducts of conjugated linoleic acids (e.g., conjugated 9,11-linoleic acid or conjugated 8,10-linoleic acid) and (meth)acrylic acid; linear aliphatic diacids having at least 5 carbon atoms (e.g., 1,12-dodecanedioic acid; 1,10-decanedioic acid; 1,8-octanedioic acid; 1,6-hexananedioic acid; 1,4-butanedioic acid); and Dimer acids. Dimer acids are dicarboxylic acids prepared by dimerizing (e.g., by Diels-Alder condensation) unsaturated fatty acids (e.g., conjugated linoleic acids) obtained from tall oil.
  • Dimer acids are dicarboxylic acids prepared by dimerizing (e.g., by Diels-Alder condensation) unsaturated
  • Z 1 and Z 2 independently represent aliphatic hydrocarbylene groups having from 1 to 30 carbon atoms. In some embodiments, Z 1 and Z 2 independently represent aliphatic hydrocarbylene groups having from 1 to 18 carbon atoms. In some embodiments, Z 1 and Z 2 independently represent aliphatic hydrocarbylene groups having from 1 to 12 carbon atoms. In some embodiments, Z 1 and Z 2 independently represent a covalent bond or a linear alkylene group having from 1 to 4 carbon atoms.
  • the fluxing curing agent comprises a Diels-Alder adducts of conjugated 9,11-linoleic and acrylic acid represented by the formula:
  • C 21 Fluxing Agent wherein one of R 1 and R 2 represents H, and one of R 1 and R 2 represents CO 2 H (hereinafter referred to as C 21 Fluxing Agent).
  • One exemplary such compound is 5(or 6)-carboxy-4-hexylcyclohex-2-ene-1-octanoic acid (hereinafter C 21 Diacid), which has the Chemical Abstracts Service (CAS) Number 53980-88-4, which is available from chemical suppliers, or, for example, by Diels-Alder condensation of a conjugated 9,11-linoleic acid (i.e., CAS No.: 121250-47-3, CH 3 (CH 2 ) 5 CH ⁇ CH—CH ⁇ CH(CH 2 ) 7 CO 2 H), which is available from chemical suppliers.
  • CAS Chemical Abstracts Service
  • C 21 Diacid is combined with one or more tall oil fatty acids, which may comprise at least one tall oil fatty acid (e.g., at least one C 18 mono-unsaturated tall oil fatty acid).
  • tall oil fatty acids e.g., at least one C 18 mono-unsaturated tall oil fatty acid.
  • DIACID 1525 is available as DIACID 1525 from MeadWestvaco, Richmond, Va.
  • the at least one diacid compound according to the formula: HO 2 C—Z 1 CH 2 CH 2 CH 2 —Z 2 —CO 2 H may comprise at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or even at least 99 percent of the total weight of carboxylic acids and anhydrides present in the curable composition.
  • the fluxing curing agent comprises at least 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, or even at least 99 percent by weight of C 21 Fluxing Agent. In some embodiments, the fluxing curing agent comprises at least 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, or even at least 99 percent by weight of a mixture of C 21 Fluxing curing agent and at least one tall oil fatty acid.
  • the curable composition may further comprise a polyol, desirably an aromatic polyol which copolymerizes with the polyepoxide to modify the physical properties of cured polyepoxide.
  • a polyol desirably an aromatic polyol which copolymerizes with the polyepoxide to modify the physical properties of cured polyepoxide.
  • suitable polyols include bisphenol A and bisphenol F. If present, the polyol may be used, for example, in an amount of from 30 to 150 percent by weight of the at least one polyepoxide.
  • the curable composition may further comprise additional ingredients such as, for example, dispersants, fillers, tougheners, antioxidants, plasticizers, stabilizers, and polymeric binder resins.
  • the curable composition may include one or more organic solvents that have sufficient volatility that they are substantially removed by drying.
  • organic solvents include, for example, ketones (e.g., acetone, methyl ethyl ketone), esters (e.g., butyl acetate, ethyl acetate), aromatic hydrocarbons (e.g., toluene), ethers (e.g., tetrahydrofuran, methyl t-butyl ether), and chlorinated hydrocarbons (e.g., dichloromethane, chloroform).
  • ketones e.g., acetone, methyl ethyl ketone
  • esters e.g., butyl acetate, ethyl acetate
  • aromatic hydrocarbons e.g., toluene
  • ethers e.g., tetrahydrofuran, methyl t-butyl ether
  • chlorinated hydrocarbons
  • Weight percentages may be influenced substantially by the specific choice of metals included in the curable composition.
  • the curable composition comprises on a weight basis: 1 to 6 parts (in some embodiments, 2 to 5 parts) of the at least one polyepoxide (e.g., a pendant epoxy functional acrylic copolymer of butyl acrylate (50-70% by weight) and glycidyl methacrylate (30-50% by weight); 0.5 to 3 parts (in some embodiments, 1 to 2 parts) of the hydroxyalkyl-substituted tertiary amine (e.g., triethanolamine); 45 to 55 parts (in some embodiments, 47 to 53 parts) of high-melting metal particles having a melting point above 300° C.
  • the at least one polyepoxide e.g., a pendant epoxy functional acrylic copolymer of butyl acrylate (50-70% by weight) and glycidyl methacrylate (30-50% by weight
  • 0.5 to 3 parts in some embodiments,
  • the curable composition may further comprise 2 to 5 parts (in some embodiments, 2 to 4 parts) of an aromatic polyol (e.g., bisphenol A).
  • an aromatic polyol e.g., bisphenol A
  • the curable compositions, and especially the resulting cured composition after at least partial curing, are desirably electrically and/or thermally conductive, although these are not requirements.
  • Curable compositions may be prepared by any suitable method including, for example, by combining the components while mixing with optional mild heating. Curing can be achieved by heating, for example, to a temperature above 170° C., typically above 190° C. or even above 220° C.
  • Curable compositions according to the present disclosure are useful, for example, for preparing adhesive articles.
  • An adhesive article comprising a curable composition according to the present disclosure is shown in FIG. 1 , wherein adhesive article 100 comprises a layer 110 of curable composition according to the present disclosure disposed on removable liner 120 .
  • Suitable removable liners include substrates that can be cleanly separated (e.g., by peeling) from the curable composition.
  • removable liners include polyolefin films, siliconized (i.e., release coated) polyester films, and siliconized papers.
  • Adhesive articles according to the present disclosure may, for example, be in roll form (e.g., a tape) or may comprise a sheet or stack of sheets. In some embodiments, the curable composition may be sandwiched between two removable liners.
  • composite article 200 comprises a semiconductor wafer 230 (e.g., a silicon wafer, germanium wafer, gallium-arsenide wafer, gallium-phosphorus wafers, or gallium-arsenic-aluminum wafer) having layer 110 of curable composition according to the present disclosure affixed to it.
  • layer 110 of curable composition is in contact with semiconductor wafer 230 , although the presence of one or more optional intermediate layers is also contemplated.
  • Optional layer 240 of detackifiable pressure-sensitive adhesive is disposed on the layer 110 of curable composition.
  • layer 110 of curable composition is partially cured to the B-stage (e.g., by heating) prior to disposing layer 240 thereon.
  • Optional polymeric film backing 250 is disposed on layer 240 of detackifiable pressure-sensitive adhesive.
  • Suitable detackifiable pressure-sensitive adhesives are well-known and described, for example, in U.S. Pat. No. 4,965,127 (Ebe et al.) and U.S. Pat. No. 6,759,121 (Alahapperuma et al.).
  • Composite articles according to the present disclosure can be made by affixing (e.g., by laminating) a layer of a curable composition according to the present disclosure to a semiconductor active device, typically on a back side opposite the active surface comprising the electronic components.
  • a layer of detackifiable pressure-sensitive adhesive disposed (e.g., by laminating) onto the layer of the curable composition. If the curable composition has the consistency of a paste or liquid it may be coated by syringe or screen printing, for example.
  • Curable compositions according to the present disclosure are useful, for example, for bonding active devices to a substrate by disposing the curable adhesive between the active device and the substrate and at least partially curing the curable composition.
  • active devices include semiconductor dies and wafers have an active surface (e.g., with one or more electronic components formed thereon) and a back side opposite the active surface.
  • the curable composition is applied to the back side although this is not a requirement.
  • suitable substrates include heat-spreader, printed circuit boards, lead frames, interposers, and flex circuits.
  • the present disclosure provides a curable composition comprising:
  • high-melting metal particles having a melting point above 300° C.
  • low-melting metallic particles having a melting point of less than or equal to 300° C.
  • a fluxing curing agent comprising:
  • the present disclosure provides a curable composition according to the first embodiment, wherein Z 1 and Z 2 independently represent aliphatic hydrocarbylene groups having from 1 to 18 carbon atoms.
  • the present disclosure provides a curable composition according to the first or second embodiment, wherein Z 1 and Z 2 independently represent a covalent bond or a linear alkylene group having from 1 to 4 carbon atoms.
  • the present disclosure provides a curable composition according to the first or second embodiment, wherein the at least one diacid compound comprises a Diels-Alder adduct of conjugated 9,11-linoleic and acrylic acid represented by the formula
  • R 1 and R 2 represents H, and one of R 1 and R 2 represents CO 2 H.
  • the present disclosure provides a curable composition according to the first or second embodiment, wherein the compound is selected from the group consisting of: Diels-Alder adducts of conjugated 9,11-linoleic and acrylic acid; 1,12-dodecanedioic acid; 1,10-decanedioic acid; 1,8-octanedioic acid; 1,6-hexananedioic acid; 1,4-butanedioic acid; and dimer acids.
  • the present disclosure provides a curable composition according to any one of the first to fourth embodiments, wherein the fluxing curing agent further comprises at least one tall oil fatty acid.
  • the present disclosure provides a curable composition according to any one of the first to sixth embodiments, wherein the low-melting metallic particles comprise an alloy comprising at least one of tin, indium, or bismuth.
  • the present disclosure provides a curable composition according to any one of the first to seventh embodiments, wherein the high-melting metal particles comprise copper particles.
  • the present disclosure provides a curable composition according to any one of the first to eighth embodiments, wherein the at least one polyepoxide comprises a solid non-polymeric polyepoxide and a polymeric polyepoxide.
  • the present disclosure provides a curable composition according to the ninth embodiment, wherein the polymeric polyepoxide comprises an acrylic polymer having pendant epoxy groups.
  • the present disclosure provides a curable composition according to any of the first to tenth embodiments, wherein the hydroxyalkyl-substituted tertiary amine comprises a compound represented by the formula: NR 3 R 4 R 5
  • the present disclosure provides a curable composition according to the eleventh embodiment, wherein R 3 , R 4 , and R 5 represent 2-hydroxyethyl groups.
  • the present disclosure provides a curable composition according to any of the first to twelfth embodiments, wherein the curable composition comprises on a weight basis:
  • the present disclosure provides a curable composition according to any of the first to thirteenth embodiments, further comprising 2 to 5 parts of an aromatic polyol.
  • the present disclosure provides a curable composition according to any of the first to fourteenth embodiments, wherein if the curable composition is at least partially cured it becomes electrically conductive.
  • the present disclosure provides an adhesive article comprising a layer of the curable composition according to any one of the first to fifteenth embodiments disposed on a removable liner.
  • the present disclosure provides a composite article comprising:
  • the present disclosure provides a composite article according to the seventeenth embodiment, wherein the active device comprises a semiconductor wafer or a semiconductor die.
  • the present disclosure provides a composite article according to the eighteenth embodiment, further comprising a layer of detackifiable pressure-sensitive adhesive disposed on the layer of the curable composition.
  • the present disclosure provides a method of making a composite article, the method comprising affixing a layer of a curable composition according to any one of the first to fifteenth embodiments to a semiconductor active device.
  • the present disclosure provides a method of making a composite article according to the twentieth embodiment, further comprising disposing a layer of detackifiable pressure-sensitive adhesive on the layer of the curable composition.
  • OEO a protected latent curing agent oligomer formed by the reaction of cyclohexene dicarboxylic anhydride and 1,2,3-trihydroxypropane prepared according to Example 1 of U.S. Pat. No. 5,376,403 (Capote et al.) TEHA triethanolamine BisPA bisphenol A BA/GMA acrylic copolymer of butyl acrylate (60% by weight) and glycidyl methacrylate (40% by weight) dissolved in acetone at 30% solids, having pendant epoxy groups, prepared according to Preparatory Example 1 of U.S. Pat. No.
  • compositions were prepared by mixing components according to the amounts in Table 1 (below).
  • compositions in Table 1 were coated using a notch bar knife onto a release coated PET polyester liner.
  • the coated films were then oven dried at 60° C. for 7 minutes to give 50 micron thick coatings.
  • Examples 1 and 2 showed ideal sintering behavior by DSC initially after coating/drying. After 4 weeks of aging at room temperature, the Comparative Example B no longer showed ideal sintering behavior by DSC. There was no 270° C. endotherm in the re-scan, indicating there was no pure Bi present, and there were lower temperature broad endotherms present in the re-scan indicating incomplete sintering. Examples 1, 2 and Comparative Example A all showed ideal sintering behavior after 6 months of aging at room temperature.
  • Examples 1 and 2 were tested for dicing and die attach properties, and for electrical conductivity and thermal conductivity properties after curing.
  • the general procedure for testing was lamination to a semiconductor wafer backside at 60° C. followed by thermal B-stage at 100° C. for 10 minutes. The liner was then removed and the B-staged adhesive was laminated to a UV de-tack dicing tape (available as ULTRON 1020R UV-sensitive tape (PVC), 95 ⁇ m thick, with backing film from MINITRON elektronik GmbH, Ingolstadt, Germany). Dicing was carried out using a dicing saw. The dicing tape was exposed to ultraviolet light (200 mJ/cm 2 dose) to detackify it, whereupon it was removed.
  • PVC UV de-tack dicing tape
  • compositions were prepared by mixing components according to the amounts in Table 2 (below).
  • compositions of Comparative Examples C and D showed incomplete sintering performance in the DSC test used for Example 1, and the reheat cycle showed no endotherm at 270° C., which is indicative of a pure bismuth phase.
  • Examples 3 and 4 showed ideal sintering behavior in the DSC test. In the reheat cycle to 300° C., the only transition was an endothermic melt of pure bismuth at 270° C. The lack of an observed exotherm in the reheat cycle also indicated that composition had been cured.
  • compositions were prepared by mixing components according to the amounts in Table 3 (below).
  • compositions of Comparative Examples E and F both of which contain too little diacid
  • the reheat cycle had a large endotherm at 200° C. and little to no endotherm at 270° C. indicating that no pure bismuth was formed. This suggests that anhydrides are not effective fluxing materials in the DSC test procedure.
  • Compositions of Examples 5 and 6 showed excellent sintering in the DSC test, and the reheat cycle showed only a strong endotherm at 270° C. indicating presence of a pure bismuth phase with no other low melting metal phases present. The lack of an observed exotherm in the reheat cycle also indicated that the compositions had been cured.
  • compositions were prepared by mixing components according to the amounts in Table 4 (below).
  • Example 7 showed partial sintering by the DSC test used for Example 1, but Example 8 with an increased level of the ethoxylated amine S202 showed complete sintering of the metal powders.
  • Comparative Examples G and H both used tertiary amines with no hydroxyl-alkyl substituents, and exhibited partial sintering in the DSC test used for Example 1 with no 270° C. endotherm present in the reheat cycle. The lack of an observed exotherm in the reheat cycle also indicated that the compositions had been cured.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Epoxy Resins (AREA)
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KR1020147033375A KR101979977B1 (ko) 2012-05-02 2013-04-05 경화성 조성물, 경화성 조성물을 포함하는 물품 및 그의 제조방법
PCT/US2013/035410 WO2013165648A1 (en) 2012-05-02 2013-04-05 Curable composition, articles comprising the curable composition, and method of making the same
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TW201410819A (zh) 2014-03-16
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US20130295311A1 (en) 2013-11-07

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